US10988826B2 - Hydrometallurgical treatment process for extraction of precious, base and rare elements - Google Patents

Hydrometallurgical treatment process for extraction of precious, base and rare elements Download PDF

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US10988826B2
US10988826B2 US16/014,340 US201816014340A US10988826B2 US 10988826 B2 US10988826 B2 US 10988826B2 US 201816014340 A US201816014340 A US 201816014340A US 10988826 B2 US10988826 B2 US 10988826B2
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metals
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hydrochloric acid
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Keith Stuart Liddell
Michael David Adams
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Lifezone Ltd
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
    • C22B3/20—Treatment or purification of solutions, e.g. obtained by leaching
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B11/00—Obtaining noble metals
    • C22B11/04—Obtaining noble metals by wet processes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B11/00—Obtaining noble metals
    • C22B11/06—Chloridising
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B13/00—Obtaining lead
    • C22B13/04—Obtaining lead by wet processes
    • C22B13/045—Recovery from waste materials
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B15/00—Obtaining copper
    • C22B15/0063—Hydrometallurgy
    • C22B15/0065—Leaching or slurrying
    • C22B15/0067—Leaching or slurrying with acids or salts thereof
    • C22B15/0069—Leaching or slurrying with acids or salts thereof containing halogen
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B23/00—Obtaining nickel or cobalt
    • C22B23/04—Obtaining nickel or cobalt by wet processes
    • C22B23/0407—Leaching processes
    • C22B23/0415—Leaching processes with acids or salt solutions except ammonium salts solutions
    • C22B23/0423—Halogenated acids or salts thereof
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B23/00—Obtaining nickel or cobalt
    • C22B23/04—Obtaining nickel or cobalt by wet processes
    • C22B23/0476—Separation of nickel from cobalt
    • C22B23/0484—Separation of nickel from cobalt in acidic type solutions
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
    • C22B3/04—Extraction of metal compounds from ores or concentrates by wet processes by leaching
    • C22B3/06—Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions, e.g. with acids generated in situ; in inorganic salt solutions other than ammonium salt solutions
    • C22B3/08—Sulfuric acid, other sulfurated acids or salts thereof
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
    • C22B3/04—Extraction of metal compounds from ores or concentrates by wet processes by leaching
    • C22B3/06—Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions, e.g. with acids generated in situ; in inorganic salt solutions other than ammonium salt solutions
    • C22B3/10—Hydrochloric acid, other halogenated acids or salts thereof
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
    • C22B3/04—Extraction of metal compounds from ores or concentrates by wet processes by leaching
    • C22B3/12—Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic alkaline solutions
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
    • C22B3/20—Treatment or purification of solutions, e.g. obtained by leaching
    • C22B3/44—Treatment or purification of solutions, e.g. obtained by leaching by chemical processes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/001—Dry processes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/006—Wet processes
    • C22B7/007—Wet processes by acid leaching
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/20—Recycling

Definitions

  • the PGMs, gold, silver and other value elements are in some cases recovered from the chloride PLS by adsorbing these elements onto ion-exchange (IX) resins or other sorbent media and subsequently recovering the elements by elution, for example using a thiourea solution.
  • PMs can be precipitated from the eluate using a caustic or ammoniacal solution to form one or more high-grade PM concentrate products for direct sale or refining, as described in International Patent Publication No. WO 99/60178.
  • the loaded resin or sorbent can be incinerated directly to produce a high-grade PM concentrate product for refining, or may be shipped directly to the refinery.
  • the direct IX route described above is not always optimal for all feed and product types, such as for cases where the PLS contains elements or species at levels that may interfere with the IX adsorption process.
  • An alternative process for the recovery and separation of precious metals and other valuable elements from PLS that meets the criteria for other feed and product types is therefore needed.
  • a hydrometallurgical process for extracting one or more saleable metals selected from the group consisting of platinum group metals (PGMs) i.e. platinum, palladium, rhodium, iridium, ruthenium and osmium; gold and silver; base metals comprising nickel, cobalt, copper, zinc, yttrium, scandium, uranium, thorium, manganese, zinc, cadmium, molybdenum, titanium, and tin; rare earth elements (REE); and rare elements comprising vanadium, germanium and gallium from a feed material containing saleable metals comprising or consisting of any one or more of a metalliferous ore; a concentrate; a solid residue from a hydrometallurgical process on a metalliferous feedstock; and a solid residue after solid-liquid separation of a product slurry from hot sulphuric acid leaching under pressure and/or atmospheric conditions from the metallife
  • PGMs platinum group metals
  • the process may further comprise a step of subjecting the solid residue from step a) to heat treatment under oxidising, neutral or reducing conditions prior to inputting the heat-treated solid residue into step d) above, or into a duplicate hot hydrochloric acid leaching step a).
  • the chlorination PLS from step d), and/or the intermediate solution product from either step b) or e) may additionally be subjected to one or more further purification and/or upgrading techniques including IX, chelating, MRT, polymeric or other sorbents, solvent extraction, precipitation using hydroxides, ammonia, carbonates or sulphides, electrowinning, reduction, or other techniques known to those skilled in the art based on techno-economic considerations to produce further intermediate solid residues for the recovery of PGMs, gold and silver, as well as any minor associated and other valuable base, REE or rare metals and further intermediate solution products for inputting into step f).
  • further purification and/or upgrading techniques including IX, chelating, MRT, polymeric or other sorbents, solvent extraction, precipitation using hydroxides, ammonia, carbonates or sulphides, electrowinning, reduction, or other techniques known to those skilled in the art based on techno-economic considerations to produce further intermediate solid residues for the recovery of PGMs, gold and silver,
  • the solid residue containing saleable metals may be separated from the saleable metal sulphates in solution by filtration or by any other solid/liquid separation means known to those skilled in the art.
  • the process may further comprise a step of separating solid residue from the saleable metal chlorides in solution from step a), b), c), d), e) and/or, where relevant from the further intermediate solution products and then providing the resultant separated solution to the relevant next step in the process.
  • the step of separating may be performed by filtration, or by any other solid/liquid separation means known to those skilled in the art.
  • the feed material ore, concentrate, or residue may be initially processed by crushing, milling or may be as-mined. Alternatively, or in addition, the feed material may be subjected to a beneficiaation step to produce an intermediate ore product for providing to the reaction vessel.
  • the beneficiaation step may be performed by a combination of crushing, grinding, screening, sizing, classification, magnetic separation, electrostatic separation, flotation or gravity separation thereby to concentrate the valuable metals or reject a gangue component, or by other means of beneficiation known to those skilled in the art.
  • the thermal treatment may be performed at from or about 80-750° C. for up to 120 minutes, typically at from or about 300-700° C. for 10 to 30 minutes, under oxidizing, neutral or reducing conditions, to remove volatile components from the solid residue and reduce or negate any preg-robbing attributes of the material, whilst rendering refractory mineral phases such as PGM-bearing minerals or silver jarosites suitable for recovery by subsequent leaching.
  • An additional second thermal treatment may be performed at from or about 500-1000° C. for up to 120 minutes, typically at from or about 700-1000° C. for 30 to 120 minutes, under oxidizing, neutral or reducing conditions, to condition saleable metals to be soluble in chloride leaching medium.
  • a third additional thermal treatment may be performed at from or about 100-600° C. for up to 240 minutes, typically at from or about 100-400° C. for 60-180 minutes, under oxidizing, neutral or reducing conditions, to further condition saleable metals to be soluble in chloride leaching medium.
  • the thermal processes may be performed as individual steps of a sequential thermal treatment process, or as one combined step.
  • the off-gases discharging from one or more of the thermal treatment steps, or any reducing gas such as syngas, carbon monoxide or hydrogen, may be further utilised by sparging into the slurry in step a) or the hydrochloric acid solution in step b) or the chlorination PLS in step e).
  • a reducing off-gas may reduce precious metals such as PGMs or gold in solution, converting them to metals that report to the solid phase for recovery in the subsequent chlorination step d).
  • the gold or PGMs in solution in steps b) or e) may be recovered by reductive precipitation using a reducing off-gas.
  • the chlorination PLS of step d) and/or the intermediate solution product of step b), step e) and/or where relevant the further intermediate solution product in the first embodiment above may be subjected to a sorption step whereby saleable metals are adsorbed on to a resin or sorbent and base metals are discharged in a solution.
  • the chlorination PLS of step d) and/or the solution product of step b), step e) and/or where relevant the further intermediate solution product in the first embodiment above may be subjected to precipitation and purification comprising or consisting of any one or more of the following steps:
  • the discharge solution from step B. and/or the intermediate solution product from step b), e) and/or where relevant the further intermediate solution product of the first embodiment of the invention may be subjected to a hydrochloric acid, calcium and residual base metal recovery and separation step comprising or consisting of:
  • the recovered hydrochloric acid may be recycled back into the hydrochloric acid leach step a) and/or the chlorination leach step d).
  • the barren solution from step c) and/or step f) may be recycled to step b) as makeup water, also allowing for reuse of hydrochloric acid.
  • the saleable metal sulphates in solution of the feed material of the first embodiment of the invention may comprise metal sulphate salts, such as copper, nickel, cobalt, rhodium, ruthenium, iridium, vanadium, germanium, gallium or scandium.
  • the feed material of the first embodiment of the invention may comprise either an individual material or a blend of refractory and non-refractory materials differing in nature.
  • the process of the invention may optionally further comprise or consist of an initial step of subjecting the hydrochloric acid solution of step a) and/or the chlorination PLS of step d) (i.e. the chloride PLS) to an ageing step for crystallisation of silica, comprising or consisting of:
  • the process of the invention may optionally comprise an initial step of subjecting any one or more of the hydrochloric acid solution of step a), the chlorination PLS of step d), the intermediate solution products from step b), c) or e), and the further intermediate solution product to a concentration step to produce a concentrated solution by any one or more of:
  • the sorption steps of the process may comprise or consist of any one or more of the following steps:
  • the elution step II. may be performed using a solution comprising acidic thiourea, salts of sulphite or hydrosulphite or chloride, or other eluants known to those skilled in the art.
  • technologies such as precipitation or crystallization may be employed in the process to produce a potentially saleable or storable ferric or ferrous hydroxide or sulphate or chloride product while recovering sulphuric or hydrochloric acid into a stream suitable for recycling.
  • technologies such as solvent extraction may be employed in the process, for example on the hot sulphuric acid pressure leach PLS, to produce a potentially useable, saleable or storable sulphuric acid product and/or recovering sulphuric acid into a stream suitable for recycling; or on the hot hydrochloric acid PLS, to produce a potentially useable, saleable or storable hydrochloric acid and/or iron chloride product, and/or recovering hydrochloric acid into a stream suitable for recycling.
  • the hydrochloric acid leach solution of step a) or c) and/or the chlorination leach solution of step d) of the first embodiment of the invention may contain iron chloride and may be treated by pressure, precipitation or crystallization, concentrated by evaporation, reverse osmosis, nanofiltration or other membrane technology, solvent extraction or ion exchange or treated by sparging/rectification, pyrohydrolysis, hydrothermal or other technology known to those skilled in the art to produce an iron-bearing product.
  • the hydrochloric acid leach or brine leach solution of step a), b) or c) may be neutralised with limestone to precipitate ferric hydroxide and other gangue elements and produce a calcium chloride filtrate, which may be evaporated and the calcium removed by sulphuric acid addition.
  • the hydrochloric acid, brine or calcium chloride filtrate may then be recycled to step a) or d) above.
  • the chlorination leaching medium of step d) may comprise hydrochloric acid or saline brine in conjunction with an oxidising agent such as chlorine, hypochlorite, hydrogen peroxide or other oxidising agents known to those skilled in the art and the leaching step may be performed under oxidising conditions, thereby to generate a chlorination PLS containing one or more saleable elements comprising or consisting of PGMs, Au, Ag, Ni, Co, Cu, REE, Y, Sc, U, Th, Zn, Mn, Cd, Mo, V, Sn and Ti.
  • an oxidising agent such as chlorine, hypochlorite, hydrogen peroxide or other oxidising agents known to those skilled in the art
  • the leaching step may be performed under oxidising conditions, thereby to generate a chlorination PLS containing one or more saleable elements comprising or consisting of PGMs, Au, Ag, Ni, Co, Cu, REE, Y, Sc, U, Th, Zn, Mn, Cd, Mo
  • the chlorination PLS generated in step d) may contain one or more saleable elements comprising or consisting of PGMs, Au, Ag, as well as Ni, Co, Cu, REE, Y, Sc, U, Th, Zn, Mn, Cd, Mo, V, Sn and Ti and may be subjected to separation and/or recovery of the one or more saleable elements by means of techniques such as solvent extraction, IX, precipitation using hydroxides, carbonates or sulphides, electrowinning, reduction and other techniques known to those skilled in the art based on techno-economic considerations.
  • the chlorination leaching step d) may comprise a less acidic chloride leaching medium having a pH of between about 2.5 and 7.5 held at a temperature in the range of between about or from 50-150° C.
  • the chlorination leaching step d) may comprise a chloride leaching medium with a free acidity of between about or from 50 to 300 g/L HCl held at a temperature in the range of between about or from 50-150° C.
  • the chlorination leaching step d) may be performed by atmospheric or pressure autoclave leaching with saline brine under oxidising conditions.
  • a hydrometallurgical process for extracting one or more saleable metals selected from the group consisting of precious elements comprising platinum group metals (PGMs) i.e. platinum, palladium, rhodium, iridium, ruthenium and osmium; gold and silver; base metals comprising nickel, cobalt, copper, zinc, yttrium, scandium, uranium, thorium, manganese, zinc, cadmium, molybdenum, titanium, and tin; rare earth elements (REE); and rare elements comprising vanadium, germanium and gallium from a feed material containing saleable metals, comprising or consisting of any one or more of a metalliferous ore; a concentrate; a solid residue from a hydrometallurgical process; and a solid residue after solid-liquid separation of a product slurry from hot sulphuric acid leaching under pressure and/or atmospheric conditions from the metalliferous ore,
  • PGMs platinum group metals
  • the product slurry of step i. or its filtrate after solid-liquid separation may further be subjected to scavenging recovery of any dissolved PGMs, base metals, iron and sulphur species by techniques known to those skilled in the art including precipitation, crystallisation, reduction, ion exchange or solvent extraction, and concentration steps such as vacuum crystallisation or membrane separation.
  • the solid residue from the hot sulphuric acid leaching may be smelted prior to leaching with hot hydrochloric acid or brine.
  • Any one or more of the processes of the invention may be integrated into an existing process including for example, a “Kell Process” as described in WO 99/60178, (see FIG. 1 ), or a modified Kell Process as described in WO2014/009928 Australian Patent Application No. 2013263848, or South African Patent Application No. 2014/08682 or a conventional heap or tank leaching process for base metal recovery.
  • a “Kell Process” as described in WO 99/60178, (see FIG. 1 )
  • a modified Kell Process as described in WO2014/009928 Australian Patent Application No. 2013263848, or South African Patent Application No. 2014/08682 or a conventional heap or tank leaching process for base metal recovery.
  • FIG. 1 is a simplified block flowsheet diagram of one possible embodiment of the process (heat treatment units are optional, depending on the feed material);
  • FIG. 2 is a simplified block flowsheet diagram illustrating more detail of one example of its implementation (heat treatment units are optional, depending on the feed material);
  • FIG. 3 shows the hot HCl leaching for extraction of base metals and iron from a pressure leach residue from a 14% Fe, 11% S high-sulphide PGM concentrate
  • FIG. 4 shows the hot HCl leaching for extraction of base metals and iron from a pressure leach residue from a 13% Fe, 5% S low-sulphide PGM concentrate
  • FIG. 5 shows the hot HCl leaching for extraction of base metals and iron from a pressure leach residue from a refractory gold concentrate
  • FIG. 6 shows the hot HCl leaching for extraction of base metals and iron from a pressure leach residue from a copper-gold concentrate.
  • the current invention provides a hydrometallurgical process for the recovery and separation of valuable precious, base or rare elements from a feed material comprising ores, concentrates and other materials.
  • the process is a process integrated into one or more existing valuable element extraction processes.
  • One embodiment of the present invention describes a novel way of quantitatively removing additional base, rare and gangue elements from pressure leach residue, allowing for increased efficiency of further treatment of the solids for valuable metals recovery, and comprises or consists of the steps of:
  • the innovation allows for the efficient removal of iron and other gangue elements from the process, potentially decreasing reagent consumptions.
  • Hydrochloric acid is found to leach gangue elements more rapidly and completely than other acids such as sulphuric acid.
  • removal of these gangue elements decreases the mass flow for downstream treatment, and effectively removes potential reagent consumers in the optional heat treatment step and non-optional chlorination leach step.
  • the process of the invention does not require the use of cyanide or mercury; toxic chemicals that are conventionally used in precious metals processing that require stringent safety and environmental controls. Moreover, the process of the invention provides an alternative, environmentally responsible method for extraction of precious metals that does not generate SO 2 and other pollutants which are detrimental to the environment.
  • Refractory is typically taken to mean a gold-bearing material that yields less than 90% gold and/or silver recovery when subjected to cyanide leaching, even under highly excess cyanide additions.
  • “Saleable metals”, “saleable elements”, “valuable metals”, “value metals” or “value elements” are used interchangeably and mean any element or metal that is able to generate a revenue through sale of the element or metal in metallic form or as a salt or precipitate of the metal or element.
  • saleable metals include any one or more of: the precious metals, base metals, REEs and rare metals.
  • PGMs mean ruthenium (Ru), rhodium (Rh), palladium (Pd), osmium (Os), iridium (Ir), and platinum (Pt).
  • Precious metals means gold, (Au), silver (Ag), and PGMs in the few instances where precious metals bearing ores also contain associated minor PGMs.
  • base metals means industrial non-ferrous metals excluding the precious metals, such as copper, lead, nickel, tin, tungsten, zinc, cadmium, manganese, cobalt, uranium, thorium, molybdenum and titanium.
  • precious metals such as copper, lead, nickel, tin, tungsten, zinc, cadmium, manganese, cobalt, uranium, thorium, molybdenum and titanium.
  • “Rare earth elements” means a group of chemically similar metallic elements comprising the lanthanide series (fifteen elements), and also includes scandium and yttrium as they because they tend to occur in the same ore deposits as the lanthanides and exhibit similar chemical properties.
  • “Rare metals” means a group of metals including vanadium, germanium and gallium, and other nominal valuable metals that may be worth recovering.
  • “KellGold” denotes the process described in South African Patent Application No. 2014/08682. “Kell” denotes the core process described in International Patent Publication No. WO 99/60178 and modified processes described in associated patents WO2014/009928 or Australian Patent Application No. 2013263848 (all incorporated herein by reference) for recovery of PGMs and base metals from concentrates.
  • Hot sulphuric acid leach means a process of hot sulphuric acid (H 2 SO 4 ) leaching comprising either or a combination of a conventional atmospheric (20-100° C.), low (100-130° C.) medium (130-220° C.) or high (220-260° C.) temperature and pressure leach using sulphuric acid.
  • “Hot hydrochloric acid or HCl leach” denotes the process whereby elements are leached from a solid feed by hydrochloric acid or acidified saline brine without addition of an oxidising acid such as chlorine gas or a reductant, or with addition of a reducing agent such as metal powders, sulphur dioxide producing chemicals, organic reagents, sulphide compounds or concentrates to achieve an oxidation-reduction potential (ORP) setpoint.
  • the leach is performed at atmospheric pressure and at a temperature of from about 60° C. to 90° C., more preferably at about 70° C.
  • Chlorination leach means a conventional atmospheric (20-100° C.) or low (100-130° C.) temperature and pressure leach under oxidising conditions whereby elements are leached from a solid feed by hydrochloric acid (HCl) or saline brine in conjunction with an oxidising agent such as chlorine, hypochlorite, nitric compounds, hydrogen peroxide or others known to those skilled in the art.
  • HCl hydrochloric acid
  • saline brine in conjunction with an oxidising agent such as chlorine, hypochlorite, nitric compounds, hydrogen peroxide or others known to those skilled in the art.
  • An “atmospheric leach step” means a conventional atmospheric (20-100° C.), temperature and pressure leach.
  • cooling and aging in the context of this application means allowing PLS or other process liquor to stand for a period of time, optionally with addition of seed solids from a subsequent solid-liquid separation step and optionally with external cooling applied.
  • Conventional smelting and refining techniques include smelting, converting and other pyrometallurgical processes under conditions whereby the input solids are melted or vaporised and are well known to those skilled in the art.
  • “Saline brine” is a high-concentration solution of salt (usually chloride, with counterions comprising metals such as sodium, potassium, magnesium, calcium, aluminium, iron or other cations) in water.
  • “Scavenging recovery” means recovery of any dissolved metals or elemental species by techniques including precipitation, crystallisation, reduction, ion exchange or solvent extraction, and concentration steps such as vacuum crystallisation or membrane separation.
  • a particular embodiment of the invention is a hydrometallurgical process for extracting saleable elements including precious, base and rare metals, from a range of quite different feed materials comprising refractory, non-refractory or intractable material types.
  • the process innovation developed by the applicant is the ability to obtain high precious metal recoveries, particularly gold and/or silver, along with by-products such as Cu, Ni, Co, Zn, Mn, Sc, H 2 SO 4 , S, PGMs and others by standard chlorination processes, but where there is sequential selective upfront removal of base metals, sulphur and gangue elements such as iron, prior to chlorination.
  • the process of the invention completely avoids the use of toxic substances such as cyanide or mercury-bearing reagents in the recovery process, and also avoids the emission of pollution to the atmosphere of toxic substances such as sulphur dioxide (SO 2 ) or arsenic trioxide (As 2 O 3 ) to the environment.
  • toxic substances such as cyanide or mercury-bearing reagents
  • SO 2 sulphur dioxide
  • As 2 O 3 arsenic trioxide
  • the feed materials input into the process can be as-mined, as-received or may be comminuted to a finer grain size.
  • the input feed materials may also have been subjected to a previous remediation step such as screening, sizing, classification, magnetic separation, electrostatic separation, dense media sepration, radiometric sorting, optical sorting, gravity separation, or others known to those skilled in the art, to concentrate the valuable metals or reject a gangue component.
  • a previous benefication step such as screening, sizing, classification, magnetic separation, electrostatic separation, dense media sepration, radiometric sorting, optical sorting, gravity separation, or others known to those skilled in the art, to concentrate the valuable metals or reject a gangue component.
  • a previous benefication step such as screening, sizing, classification, magnetic separation, electrostatic separation, dense media sepration, radiometric sorting, optical sorting, gravity separation, or others known to those skilled in the art, to concentrate the valuable metals or reject a gangue component.
  • the first step comprises subjecting a feed material which may be a concentrate ( 10 ) to a hot sulphuric acid (H 2 SO 4 ) leaching step ( 12 ) under pressure and/or atmospheric conditions (“hot sulphuric acid leaching”) to produce a product slurry ( 14 ) comprising valuable metal sulphates in solution and a solid residue containing precious metals.
  • a feed material which may be a concentrate ( 10 ) to a hot sulphuric acid (H 2 SO 4 ) leaching step ( 12 ) under pressure and/or atmospheric conditions (“hot sulphuric acid leaching”) to produce a product slurry ( 14 ) comprising valuable metal sulphates in solution and a solid residue containing precious metals.
  • the solid residue is then separated from the metal sulphates in solution by a means of solid/liquid separation, such as by filtration or other means known to those skilled in the art.
  • Saleable base metals and excess sulphuric acid may be recovered by a base metal recovery step ( 18 ) from any of the solutions comprising metal sulphates, including the initial sulphuric acid leach product slurry by means of techniques such as solvent extraction, ion exchange, precipitation using hydroxides, ammonia, carbonates or sulphides, electrowinning, reduction, recycling and other techniques known to those skilled in the art based on techno-economic considerations.
  • the H 2 SO 4 leach product solid residue ( 16 ) is further treated by hot hydrochloric acid (HCl) leaching at atmospheric pressure and at 70° C., with no added oxidant or reductant, or under reducing conditions ( 20 ), also referred to as a “HCl Preleach”, allowing removal or conversion of excess iron from the solid residue into a HCl solution for removal by iron solvent extraction, precipitation or other means known to those skilled in the art.
  • HCl Preleach hot hydrochloric acid
  • reductant such as metal powders, sulphur dioxide producing chemicals, organic reagents, sulphide compounds or concentrates, may optionally be added to the HCl Preleach ( 20 ) to achieve an oxidation-reduction potential (ORP) setpoint.
  • non-oxidising or reducing HCl leach ( 20 ) solid residue may first be subjected to thermal treatment ( 24 ) to render the valuable metals leachable, and may produce off-gases comprising sulphur and the off-gases may then be subjected to a process of recovering sulphur ( 26 ):
  • the thermal treatment ( 24 ) would be performed at about 80-750° C. for up to 120 minutes, preferably at about 300-700° C. for 10 to 30 minutes, under oxidizing, neutral or reducing conditions, to remove volatile components from the solid residue and reduce or negate the preg-robbing properties of the material.
  • the thermal treatment may comprise a second heating step if necessary at about 500-1000° C. for up to 120 minutes, preferably at about 700-1000° C. for 30 to 120 minutes, under oxidizing, neutral or reducing conditions, to condition valuable metals to be soluble in chloride leaching medium. Additionally, this step can negate or modify any preg-robbing and encapsulation or coating properties of carbonaceous and clay minerals, thereby unlocking precious metals for subsequent chlorination leaching.
  • a third additional heating step may be performed if necessary at about 100-400° C. for up to 120 minutes, preferably at about 150-300° C. for 30 to 120 minutes, under oxidizing, neutral or reducing conditions, to condition valuable metals such as Au, Ag, as well as Pt, Pd, Rh, Ru, Ir, Os (i.e. PGMs), Ni, Co, Cu, REE, Y, Sc, U, Th, Zn, Mn, Cd, Mo, V, Ti, Ge, Ga to be soluble in the chlorination leaching medium. Additionally, this step can further negate or modify any preg-robbing and encapsulation or coating properties of carbonaceous and clay minerals, thereby unlocking precious metals for chlorination leaching.
  • valuable metals such as Au, Ag, as well as Pt, Pd, Rh, Ru, Ir, Os (i.e. PGMs), Ni, Co, Cu, REE, Y, Sc, U, Th, Zn, Mn, Cd, Mo,
  • These heating steps of the thermal treatment ( 24 ) may be performed as individual steps of a sequential thermal treatment process, or as one combined step.
  • the off-gases discharging from one or more of the thermal treatment steps ( 24 ), or the feed gas may be further utilised by sparging into the HCl leach step ( 20 ) product slurry, or the separated hydrochloric acid solution from the HCl leach product slurry, or into the chlorination PLS after oxidising chlorination leaching ( 28 ).
  • a reducing off-gas may be used to reduce precious metals such as PGMs or gold in solution, converting them to metals that report to the solid phase for recovery in the subsequent oxidising chlorination step ( 28 ) of the process.
  • the gold or PGMs in solution from either the HCl leach ( 20 ) or chlorination leaching ( 28 ) may be recovered by reductive precipitation using a reducing off-gas.
  • the hydrochloric acid solution comprising metal chlorides is subjected to a purification and/or upgrade step comprising any one or more of solvent extraction, ion exchange (IX), chelating, molecular recognition technology (MRT), polymeric or other sorbents; precipitation using hydroxides, ammonia, carbonates or sulphides, electrowinning, reduction or other techniques known to those skilled in the art ( 22 ) based on techno-economic considerations and produces an intermediate solution product and an intermediate solid residue.
  • the intermediate solid residue is the leached in the chlorination leaching step ( 26 ).
  • the HCl leach step ( 20 ) is aimed at removal of gangue and residual base metals after H 2 SO 4 leaching recovery of the majority of the base metals.
  • the HCl used in this step can be successfully recovered in a HCl regeneration step ( 30 ) and recycled back into the process, thereby saving reagent costs.
  • the remaining barren solution ( 50 ) is relatively clean, due to the prior removal of soluble gangue and base metals in the non-oxidising or reducing HCl leach step ( 20 ) hence, this barren solution ( 50 ) may be recycled directly to the chlorination leach ( 28 ), with top-up of recovered HCl from the HCl regeneration step ( 30 ).
  • the chlorination leaching step ( 28 ) may be optimised for effective recovery and/or separation of some of the saleable elements that may be present in the multiple-composition feed. Specifically, the chlorination leaching step ( 28 ) is performed under oxidising conditions using hydrochloric acid or saline brine in conjunction with an oxidising agent such as chlorine, hypochlorite, hydrogen peroxide or others known to those skilled in the art. Valuable elements such as Au, Ag, as well as Pt, Pd, Rh, Ru, Ir, Os (i.e.
  • PGMs Ni, Co, Cu, REE, Y, Sc, U, Th, Zn, Mn, Cd, Mo, V, Ti, Ge, Ga are leached into the chlorination pregnant leach solution (PLS), leaving a solid waste residue ( 40 ).
  • Precious metals are separated and recovered ( 32 ) from chlorination PLS ( 28 ) and where warranted, may be scavenged from the previous process streams, by use of conventional methods known to those skilled in the art, including techniques such as solvent extraction, ion exchange, salt crystallisation, precipitation using hydroxides, carbonates or sulphides, electrowinning, reduction and others.
  • the commercially attractive elements separated and recovered from the chlorination PLS ( 28 ) include PGMs, gold, silver and rare metals.
  • the process of the invention allows separation of these elements from other valuable metals such as nickel, cobalt and copper, and additionally, rare earth elements, including yttrium and scandium, and uranium, thorium, vanadium, titanium, manganese, zinc and cadmium, whilst iron components may also be extracted as commercially attractive products such as pigments and nanomaterials.
  • the HCl and/or H 2 SO 4 from the process may be recycled back into the process, thereby reducing operational costs and additional amounts of metals may be recovered during this recycling process.
  • Base metals such as nickel, copper and cobalt and any minor fugitive gold, silver, PGMs or other value metals if present, can be recovered via a scavenger recovery process or are recycled along with free acid to suitable process streams earlier in the process.
  • IX, chelating e.g.
  • thiol, thiouronium, polyamine or other sorbent resins, fibres, carbons, biological materials or other materials such as solvent extractants, precipitants or reductants may be used to recover small amounts of minor fugitive PGMs, gold, silver or other value metals if present, from the process streams.
  • iron is first removed from the HCl leach ( 120 ) PLS by means of solvent extraction ( 140 ) or other routes known to those skilled in the art, such as hydroxide or carbonate precipitation.
  • the stripped solution may be subjected to hydrolysis ( 160 ) using techniques such as by means of one or more steps including preboil, rectification, distillation, adsorption, reboil, pyrohydrolysis, spray roasting, hydrothermal and/or other technique combinations known to those skilled in the art, producing a potentially saleable or dischargeable iron-bearing product ( 180 ), alternatively produced directly as a hydrolysed precipitate
  • the barren chloride stream from the non-oxidising or reducing HCl leach ( 120 ), Fe extraction ( 140 ) or hydrolysis ( 160 ), scavenger recovery ( 280 ) and/or chlorination leach ( 200 ) steps may be subjected to a preboil-rectify-reboil or sulfuric treatment ( 220 ), thereby achieving several outcomes, including recovery of strong HCl, removal of calcium, and recovery of residual metal sulphate or sulphide salts, such as copper, nickel, cobalt, rhodium, ruthenium, iridium, vanadium, germanium, gallium or scandium, for recycle or recovery.
  • the hydrochloric acid leach or brine solution may be neutralised with limestone ( 140 ) to precipitate ferric hydroxide and other gangue elements ( 160 ) and produce a calcium chloride filtrate which may be subjected to scavenger recovery of any residual value metals ( 280 ) using a sorbent or precipitant, then evaporated and the calcium removed by sulfuric acid addition ( 220 ).
  • the hydrochloric acid, brine or calcium chloride filtrate may then be recycled directly to HCl Preleach ( 120 ) or chlorination ( 200 ).
  • the barren chloride solutions ( 50 , 220 , 240 ) may be treated by exploiting differences in solubility of metal sulphates under selected conditions.
  • the barren chloride solutions ( 50 , 220 , 240 ) may be contacted with 70% H 2 SO 4 and then preheated in a pre-boil stage in which the bulk of the HCl is boiled off for recovery. Calcium may be removed by precipitation with gypsum and the remaining solution is introduced to a distillation column where water remains largely unvolatilised, while the remaining HCl is almost completely volatilised or recycled in the remaining solution
  • Vapours from the HCl recovery ( 220 ) stages can be passed through a water-cooled absorber column where the HCl is recovered by absorption ( 260 ) into chlorination filter wash water, producing 33% HCl suitable for use in the non-oxidising or reducing HCl leach step ( 120 ) or the oxidising chlorination leach step ( 200 ) and/or while directly reusing wash water.
  • the product slurry from the HCl leaching step ( 120 ) or its fliltrate after solid-liquid separation may further be subjected to scavenging recovery of any dissolved PGMs, base metals, iron and sulphur species by techniques including precipitation, crystallisation, reduction, ion exchange or solvent extraction, and concentration steps such as vacuum crystallisation or membrane separation.
  • the solid residue from the PDX leaching step ( 100 ) may be smelted prior to providing into the reaction vessel.
  • a flotation concentrate with head assay shown in Table 3 is subjected to sulphuric acid pressure oxidation (PDX) leaching >85% nickel, cobalt and copper and ⁇ 1% iron, and the filtered and washed PDX residue is subjected to an atmospheric hot non-oxidising hydrochloric acid (HCl Preleach) leaching step to effect the removal of iron as well as residual base metals such as nickel, copper, cobalt, zinc, into a separate stream.
  • FIG. 4 shows the extractions of base metals and iron with acid dose in the HCl Preleach step. Table 4 shows a breakdown of elemental extractions in the main extraction stages.
  • a flotation concentrate with head assay shown in Table 5 is subjected to sulphuric acid pressure oxidation (PDX) leaching 34% iron, and the filtered and washed PDX residue is subjected to an atmospheric hot hydrochloric acid (HCl Preleach) leaching step to effect the removal of iron, silver and arsenic, as well as residual base metals such as copper, into a separate stream.
  • FIG. 5 shows illustrative extractions of elements with acid dose in an HCl Preleach step.
  • Table 6 shows a breakdown of elemental extractions in the three main extraction stages.
  • a flotation concentrate with head assay shown in Table 8 is subjected to sulphuric acid pressure oxidation (PDX) leaching 34% iron, and the filtered and washed PDX residue is subjected to an atmospheric hot hydrochloric acid (HCl Preleach) leaching step to effect the removal of iron, silver and arsenic, as well as residual base metals such as copper, into a separate stream.
  • FIG. 6 shows the extractions of elements with acid dose in the HCl Preleach step.
  • Table 9 shows a breakdown of elemental extractions in the three main extraction stages.

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